Presentation on Preventive Maintenance

Introduction Maintenance : Two basic categories : All activities that maintain facilities and equipment in good working order so that a system can perform as intended Two basic categories : Building and grounds Equipment maintenance

Types of Maintenance Regular Maintenance Breakdown Maintenance Generally maintenance can be done in the following four ways : Regular Maintenance Breakdown Maintenance Preventive Maintenance Total Productive Maintenance

Preventive Maintenance : Preventive Maintenance is the care and understanding of your assets basic needs, while in routine service. Preventive Maintenance can also be described as the scheduling tool or action plan for managing the anticipated life expectation of “any” asset.

Objectives To obtain maximum availability of the plant by avoiding breakdowns and by reducing the shutdown periods to a maximum. To keep the machine in proper condition so as to maintain quality of the product. By minimizing the wear and tear, preserve value of the plant. To ensure for the safety of the workers. To keep the plant at maximum production efficiency. To achieve all the above objectives with most economical combinations.

Elements of Preventive Maintenance Inspections or Check ups Lubrication Planning and Analysis Training to maintenance staff Storage of spare parts Records and Analysis

The following records are generally maintained for “ Record and Analysis “ purpose : Operation manual Maintenance instruction manual History cards and history registers Spares procurement registers Inspection register Log books

Reasons for the need of a PM system Increased Automation. Business loss due to production delays . Production of a higher quality product . Just-in-time manufacturing. Need for a more organized, planned environment.

Potential errors or damage of a P.M Damage to an adjacent equipment during a PM task. Reintroducing infant mortality by installing new parts or materials. Damage due to an error in reinstalling equipment into its original location.

When Does Preventive Maintenance Make Sense This is a logical choice that considers two conditions #1. The component in question has an increasing failure rate. #2. The overall cost of the preventive maintenance action must be “ less than the overall cost “ of a corrective action. If both of these conditions are met PM would make sense

The key for a successful PM system Scheduling – Should be automated to the maximum extent possible Execution – Should be done before the actual break down occurs.

Motivating Preventive Maintenance Workers Training programs – most effective Establish inspection and preventive maintenance as a recognized, important part of the overall maintenance program. Assign competent, responsible people to the preventive maintenance program.

Continued - Follow-up to assure quality performance and to show everyone that management does care. Provide training in precision maintenance practices and training in the right techniques and procedures for preventive maintenance on specific equipment. Set high standards. Publicize reduced costs with improved up-time and revenues, which are the result of effective preventive maintenance

Advantages These advantages are efficiently planned and well executed preventive maintenance program : Reduction in production downtime. Lesser overtime pay for maintenance personnel. Lesser number of standby equipments are needed. Less expenditure on repairs. Due to planned spare parts replacement, lesser spare parts are needed to remain in store at all times. Greater safety to employees because of reduced breakdowns.

Summary PM is not difficult to achieve. It is an essential part for cost reduction There is an element of risk involved in PM Careful planning and execution will reduce the risk of PM The biggest benefits of a PM program occur through painting, lubrication, cleaning and adjusting, and minor component replacement to extend the life of equipment and facilities.

Total Maintenance Cost Breakdown and repair cost Optimum Amount of preventive maintenance Cost Total Cost Preventive maintenance cost

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